What's the best way to increase your food production yield?

There are plenty of (can be costly) super-tech options, so I will focus on simple tools you can use now or implement quickly. ? Gemba Walks to identify on-floor issues directly. ? Value Stream Mapping to optimize material flow. ? IoT Sensors for real-time monitoring of quality and equipment. ? ML for predictive maintenance & maximum uptime. ? R-C Analysis to effectively implement change. ? ERP System to holistically improve operations. ? Process workshops for continuous production efficiency. ? Sustainable exit-strategies for overproduction & waste. Whether you invest in AI or advanced software, there are other impactful data collection methods offering real-time insight and opportunities to further improve your operation.

The tools and methodologies mentioned are all very valid but they are much more useful if built on a foundation of well trained and fully involved staff who understands their roles and contribution to the organization and are willing and able to fulfill their daily routines flawlessly

plenty of reasons leads to enhance yield and proven tools are available to dig out these reasons. The first step is to make a plant and geography based raw material specs sheets and derive a robust system to stick to those standards.

Adoption and deployment of continuous improvement methodologies can bring about increased food production yield. This will require process mapping, identification of waste/loss points, and reduction or elimination of identified waste (through critical analysis of the 4 Ms - Man, Materials, Methods, and Machine). Once the waste is identified, countermeasures can be developed to eliminate or reduce the waste followed by development and implementation of preventive measures to block future reoccurrences.

These are some steps to improve production. In production you must follow the schedule pre maintenance. maintain the efficiency of machine. Employees training according to work. Reduce the small break down. Reduce the wastage.

In all endeavors, successful output hinges on quality input. Merging tech and tenured expertise remains the formula for competitive equipment optimization. Ex. Optimization Tools: ? Fluke Tools: Ensure calibration in weight & mixing processes. ? IoT Sensors: Predictive maintenance, reducing downtime by identifying potential failure points. ? SKF System: Monitor machinery conditions to extend performance & longevity. ? AZO System: Precise ingredient scaling & waste mitigation. ? ABB’s Robot: Enhance packaging & palletizing efficiency. ? Siemen SIMATIC: Enable line adaptability for swift turnover. Recipe: KPIs, data-driven decisions, consistent process improvement and prioritized training, fuels continuous and sustainable optimization.

Balancing speed and efficiency in food manufacturing is crucial. Running equipment at its maximum speed doesn't always yield optimal results. Slowing down by 33% can increase Mean Time Between Failures, reduce defects, and prevent overfill. This change alone contributed to a remarkable 112% increase in overall efficiency since the trial and implementation in my previous experiences. Additionally, hands-on floor management is vital as it uncovers operational inefficiencies that automated systems miss, like PI Vision (great product, but doesn't beat the ol' "trust but verify" method). Achieving true efficiency requires a thoughtful, balanced approach that prioritizes quality, maintenance, and human insight.

To optimise your equipment, a robust maintenance system is required with well experienced maintenance personnel either within the factory or outsourced. The system must have a robust spare parts inventory management especially as you move towards sufistication.

Particularly minimising waste with respect to packaging and processing damage is key to improving output. Take the time to set up the system properly before starting production.

In my experience in a food line with several machines being fed by a conveyor belt was to sermonize the speed of all machines to run at the optimal speed of the slowest machine on the line. Then setup controls that shuts down the entire line if any one machine has a issue. Make the line run like a V8 motor. Then analyze that slower machine to see what is needed to speed it up. (Machines in Motion Tend to Stay in Motion. Over time and Analyzation, you will speed up the entire Production Line, and even Reduce labor on Operators on the line. In my Past I did just that and took Uptime to 98+, Raised overall Production by over 30% and reduced labor from 7 operators to 3 on the entire line.

Increasing food production yield is crucial for food manufacturing businesses. It not only positively impacts profitability but also plays a significant role in sustainability and customer satisfaction.

There is always the hidden value that would only be unlocked by adopting lean manufacturing. Wastes of raw and packaging materials, time of motion, human capital can translate to increase in yield (output) if eliminated from the value stream.

Lean are the way to go and combined with a good qms (tqm) thought in a lean way, the production yeild so rise. And a continued use of the pdca Circle

Enhanced R&D and integrated tech will continue to be a competitive strategy for optimizing yield via product innovation. Ex. Innovation + Tools NielsenIQ: Market trend insights equal innovative product development. Salesforce CRM: Create customer feedback loops, enhancing existing products. Rapid Prototyping: Quick testing to enable real-time, iterative refinement. Tableau: Data analytics, pinpointing product performance and areas for improvement. Jira: Facilitate agile product development, ensuring market relevancy. Prioritize KPIs: Product yield, consumer acceptance, and consistent quality. ETQ Reliance: Ensure food safety by integrating checks throughout development, this can greatly mitigate recall risks and missed-standards.

One thing I learned over the years is the importance for ingredients suppliers and food manufacturers to build a strong and close partnership. This gives a firm foundation for a strong collaboration between the two companies and can facilitate a successful and confidential investigation on how the food manufacture can obtain e.g. higher yields in production.

The 7th way could be : Teamwork Teamwork is essential for the success of any organization,When team members work together effectively, they can achieve higher yields and productivity For Example : 1- By sharing knowledge and expertise. This can lead to new and innovative ideas for improving the production process and ultimately will enhance Yield and productivity 2 - By splitting up tasks as per experties in areas where they are most skilled. This can lead to a more efficient and productive use of resources. 3 - By Effective Communication team members can support each others . This can help to reduce stress and improve morale, which can lead to higher productivity. Moreover, teamwork is the powerhouse of Productivity and Yied.

Develop Capabilities It will require to deeply know the science around your raw materials, products and manufacturing processes. Also, it requires to know what technology domains your company stand for or is aiming at. There is not a fixed recipe, but a clear strategic thinking and a pragmatic end-goal in mind.

Lean Manufacturing is the answer to improve all aspects of production. It is also very important to customize Lean process to suite your process. The key opportunities are creating a diverse Lean team. Using the 5s procedure, Preforming a RCFA. The most affective thing is, WHAT-WHAT. WHY-WHY. HOW-HOW. (What Happened. What caused it to happen). (Why did that happen. Why did that happen. & How do we correct it. How do we make it never happen again. Next is PMs. Predictive no Reactive. Use of Thermon imaging & Ultrasound for PMs. Next set optimal speed of all machines online to operate at a constant speed that works with the optimal speed of the line. Same as all internal parts on a V8 motor. MACHINES IN MOTION TEND TO STAY IN MOTION